Radio frequency identification labels and systems and methods for making the same

ABSTRACT

Systems and methods are provided for generating customized labels having electronic circuitry such as RFID circuitry. A printing system generates the label by selectively transfer printing elements (e.g., electronic circuitry, physical components, etc.) and donor layers (e.g., conductive materials, non-conductive materials, etc.) from a ribbon to a receiver (e.g., an item that receives the indicia). In addition, the printing system can program and test the label or indicia thereof, thereby providing the ability to customize each label according to predetermined criteria and to ensure that each label functions properly.

This application claims the benefit of U.S. Provisional Application No.60/643,851, filed Jan. 14, 2005, the disclosure of which is incorporatedby reference herein in its entirety.

BACKGROUND OF THE INVENTION

The present invention generally relates to systems and methods forprinting indicia. More particularly, the present invention relates tosystems and methods for generating customized labels that includeindicia such as radio frequency identification (RFID) technology orother electronic circuitry.

RFID technology, which is sometimes referred to in the industry as anRFID chip, RFID device, RFID tag, RFID circuitry, or RFID transponder,is known and used in many different applications. For example, RFIDtechnology can be used in identification, authentication, or trackingapplications. As another example, RFID technology can be used in placeof, or in addition to, machine readable indicia such as bar codes andother printed media.

RFID technology may include circuitry (e.g., micro-circuitry) thatprovides a signal including predetermined data. This predetermined datamay, for example, identify an item on which the RFID technology isaffixed. In other approaches, the data may represent a code, such aselectronic product code, that may specify a product manufacturer, aproduct name, and a serial number. Furthermore, the data may be writtenin a product markup language (e.g., an extensible markup language).

RFID technology may provide the predetermined data actively orpassively. In active applications, the RFID circuitry may independentlyprovide the predetermined data. That is, a power source (e.g., battery)powers the RFID circuitry and enables the RFID circuitry to transmit thedata. Actively operating RFID circuitry may continuously transmit itsdata until its power source is drained or it may transmit its data for apredetermined period of time in response to receiving an activationsignal. In passive applications, the RFID circuitry may receive and bepowered by an activation signal or an interrogation signal. Theactivation or interrogation signal may excite or power the RFIDcircuitry, causing it to provide its data while it is receiving theactivation signal. Thus, in passive applications, there is no need forthe RFID circuitry to be powered by a power source such as a battery.

RFID technology offers advantages over known bar coding or other printedidentification techniques. For example, RFID may allow manufacturers,packagers, wholesalers, distributors, retailers, or any other person orentity that contributes to a supply or distribution chain of productsfor the marketplace to more accurately maintain records of theirinventory to a degree that was previously not possible. For example,assume that a distributor ships a pallet of 1000 widgets, each of whichare labeled with RFID technology, to a retailer. When the retailerreceives the pallet, he can verify that all 1000 widgets are receivedusing his RFID sensing circuitry.

Although RFID offers many advantages, RFID technology is subject toseveral drawbacks. One drawback is that RFID is more expensive than barcoding and printed identification techniques. That is, RFID, unlike barcoding, may require circuitry to (actively or passively) provide a radiofrequency signal, which carries predetermined data (that may be used toidentify an item). In addition, in order for the RFID technology toprovide predetermined data in a radio frequency signal, the circuitrymay require customization or programming. Thus, the cost associated withRFID technology includes production cost of the circuitry, theprogramming cost, and affixing cost. While production costs may beexpected to decrease as volumes increase, the programming and affixingcosts are not as elastic. That is, such costs may remain relativelyfixed or may depend on the distribution process (e.g., processes used bydistributors to affix RFID tags to items), the supply and demand of, forexample, items being tagged with RFID technology, and other factors.

Unlike bar codes and other printed codes, known systems cannot createcustomizable label having RFID technology on demand. For example, adistributor or retailer is not able to locally create and program theRFID technology at the point of sale or use. This limitation hampers theflexibility and use of RFID, thereby contributing to its higher costs.

Another drawback often experienced with RFID technology is that theoperational range may be limited unless an antenna is used. An antennamay extend the transmission range of an RF signal transmitted by theRFID or it may extend the range in which the RFID can receive signals(similar to how an antenna improves or extends the operating range of atransistor radio). Moreover, the antennas may require customization tomeet the requirements of the RFID technology.

Further still, another drawback with conventional systems that produceRFID technology is that there may be no mechanism for testing whetherthe RFID technology is functioning properly.

Therefore, in view of the foregoing, it is an object of the presentinvention to provide systems and methods to produce customizable tags orlabels including RFID technology that alleviate the above and otherproblems with existing RFID technology and methods and systems formaking the same.

SUMMARY OF THE INVENTION

These and other objects of the present invention are accomplished inaccordance with the principles of the present invention by providingsystems and methods that generate customized labels having electroniccircuitry such as RFID circuitry. The printing system according to theinvention generates labels according to the invention by selectivelytransfer printing indicia from a ribbon to a receiver (e.g., an itemthat receives the indicia). Indicia, as defined herein, refers toanything that can be transfer printed from a ribbon to form part of alabel. For example, indicia may include elements (e.g., electroniccircuitry, physical components, etc.) and donor layers (e.g., conductivematerials, non-conductive materials, etc.). In addition, the printingsystem can program and test various indicia, thereby providing theability to customize each label according to predetermined criteria andto ensure that each label functions properly.

The ribbon may include the indicia (e.g., elements and donor layers)that are used to produce lables according to the present invention. Theindicia (e.g., elements and donor layers) may be arranged inpredetermined positions on the ribbon such that the printing system cancontrol the feed of the ribbon and selectively transfer print indicia(e.g., elements and donor layers) to a receiver. The ribbon may includeguide elements that enable the printing system to monitor the feed ofthe ribbon to ensure that the indicia are accurately transfer printed tothe receiver. Print transferring may include thermal transfer printing,which uses application of heat to effect transfer of a portion of theribbon to the receiver, or pressure transfer printing, which usesapplication of pressure to transfer a portion of the ribbon to thereceiver.

An advantage of using a ribbon according to the invention is that itgreatly improves flexibility in generating customized labels andminimizes costs over prior art systems. For example, by combiningelements (e.g., RFID circuitry, power sources, etc.) with donor layers(e.g., conductive materials, etc.), the printing system can selectivelytransfer print elements and interconnect those transferred elements bytransfer printing, for example, a conductive donor layer. If desired, acustom made antenna may be produced by selectively transfer printing oneor more donor layers. Moreover, if the ribbon includes an optical donorlayer, that layer may be transfer printed onto the receiver or on top ofelements or other donor layers to provide a machine readable or humanreadable markings.

Costs are further reduced and label customization is further enhanced byproviding “on-the-fly” or on-demand programming and testing of theelectronic circuitry (e.g., RFID circuitry) that forms part of the labelproduced by the printing system. Programming and testing of theelectronic circuitry may be performed before the electronic circuitry istransfer printed (e.g., residing on the ribbon), during transferprinting, or after the electronic circuitry is transfer printed.Programming may cause the electronic circuitry to store and transmitpredetermined data (e.g., product name, manufacturer name, serialnumber, etc.) that may be specific to each label. Testing may beperformed to test whether the electronic circuitry (e.g., transmits thecorrect data) and whether the label, itself, is functioning properly(e.g., all electrical connections have been properly transfer printed).

An advantage of the present invention is that the generation, includingtransfer printing, programming, and testing, of the label may beperformed at various points during the manufacture, distribution, orsale of an item. For example, a parts manufacturer may tag parts usingthe printing machine according to the invention with RFID technology andsend those parts to a distributor. The distributor may ship the parts toa retailer (e.g., a retail store) and use the printing machine to labelthe pallet or boxes containing those parts. The retailer, upon receiptof the parts, may use the printing machine to individually label theparts.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects and advantages of the invention will beapparent upon consideration of the following detailed description, takenin conjunction with the accompanying drawings, in which like referencecharacters refer to like parts throughout, and in which:

FIG. 1 shows an illustrative arrangement in which customized labelsincluding electronic circuitry according to the invention can be used inaccordance with the principles of the present invention;

FIG. 2 shows a block diagram illustrating various elements and materialsthat may be included on a label in accordance with the principles of thepresent invention;

FIGS. 3A and 3B show different views of a more detailed illustration ofa label that is in accordance with the principles of the presentinvention;

FIGS. 4A and 4B is the same as the label shown FIGS. 3A and 3B, butincludes an additional optical layer that is in accordance with theprinciples of the present invention;

FIGS. 5A and 5B show different views of another detailed illustrationsof a label that is in accordance with the principles of the presentinvention;

FIG. 6 shows an illustrative block diagram of a section of ribbon thatis in accordance with the principles of the present invention;

FIGS. 7A and 7B show different views of a more detailed illustration ofa ribbon in accordance with the principles of the present invention;

FIG. 8 shows an illustration of a ribbon assembly that is in accordancewith the principles of the present invention;

FIG. 9 shows a block diagram of a printing system that is in accordancewith the principles of the present invention;

FIG. 10 shows a more detailed block diagram of the printing system shownin FIG. 9 in accordance with the principles of the present invention;

FIG. 11 shows a diagrammatic illustration of a printing system that isin accordance with the principles of the present invention;

FIG. 12 shows a flowchart for printing indicia in accordance with theprinciples of the present invention;

FIG. 13 is a flowchart illustrating with more detail a ribbon feedingstep shown in FIG. 12 in accordance with the principles of the presentinvention;

FIG. 14 is a flowchart illustrating with more detail a transfer printingstep shown in FIG. 12 in accordance with the principles of the presentinvention;

FIG. 15 shows an alternative flowchart for printing indicia inaccordance with the principles of the present invention; and

FIG. 16 shows a flowchart for performing tests in accordance with theprinciples of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows an illustrative arrangement in which a customized labelaccording to the invention can be used in accordance with the principlesof the present invention. For example, FIG. 1 may represent a point in adistribution chain (e.g., manufacturer site, distributor site, orretailer site) in which labels can be affixed to a receiver. As shown inFIG. 1, printing machine 5 may be used to print label 20 (e.g., such aslabels 200, 300, 400, and 500 shown in FIGS. 2-5 and described in moredetail below) onto receiver 10. Printing system 5 is constructed inaccordance with the principles of the present invention to generatelabel 20 on demand and customize it to meet a predetermined set ofcriteria. Printing system 5 may include an input source (not shown) thatpermits, for example, a user to input the parameters or specificationsof the label to be printed, electronic circuitry (not shown) forexecuting processes to generate the label, and a display device (notshown) for displaying information. The methods and apparatus or systemfor printing labels is described in more detail below in connection withFIGS. 6-15.

Receiver 10 represents a black box abstraction of any item capable ofreceiving and retaining label 20 that is printed onto the item byprinting system 5. Examples of receives may include, but are not limitedto, items with surfaces such as paper, cardboard, wood, plastic, metal,fabric, textiles, or a TYVEC™ (sheet of high-density polyethylenefibers). Other examples of receivers may include drivers licenses,passports, postmarks, postage meter indicia, postage stamps, labels,authenticity seals or labels, certificates of authenticity, visas, pricetags, inventory control tags, access control cards, personalidentification badges, product packaging, pallet tags,anti-counterfeiting labels, currency, patient identification cards,labels and tags and similar items.

Label 20 represents a customized label that may be produced by printingsystem 5. Label 20 may be produced to fulfill many different designcriteria, ranging from relatively simple to relatively complex. Forexample, in one embodiment, label 20 includes an electronic device suchas RFID circuitry. In another embodiment, label 20 may include RFIDcircuitry, a battery, an antenna, conductors, and printed indicia. Amore detailed explanation of label 20 according to the invention isdiscussed below in connection with FIGS. 2-5.

It is understood that the depictions of printing system 5 and receiver10 are merely illustrative. Thus, although printing system 5 is depictedas a handheld device, it is not limited as such. For example, printingsystem 5 may be an industrial printing system that prints labels at ahigh capacity.

FIG. 2 shows a block diagram illustrating various elements and materialsthat may be included on label 200 in accordance with the principles ofthe present invention. As shown, label 200 may include elements 210,donor layers 220, and substrate 230. Note that elements 210, donorlayers 220, and substrate 230 may be collectively referred to asindicia. Elements 210, donor layers 220, and substrate 230 may betransfer printed from a source (e.g., ribbon) to receiver 10 usingtransfer printing according to the present invention. For example, aribbon such as ribbon 600 and 700 shown in FIGS. 6 and 7 may includeelements 210 and donor layers 220. During printing, elements 210 anddonor layers 220 are selectively transfer printed from the ribbon to thereceiver to produce the desired label. Note that although ribbon 600 (ofFIG. 6) does not include substrate 230, per se, it will be understoodthat substrate 230, as it resides on label 200, may be formed from acombination of elements 210 and/or donor layers 220 that are transferprinted from the ribbon to receiver 10. In an alternative embodiment,certain elements 210 may reside on receiver 10 prior to printing, anddonor layers and other elements 210 may reside on the ribbon.

Elements 210 may include any element having a predefined or tangibleexistence (e.g., physical structure and/or functional existence) priorto being involved with any transfer printing in accordance with theprinciples of the present invention. Thus, elements 210 that aretransfer printed onto receiver 10 are substantially the same both beforeand after printing. Examples of such elements may include electroniccircuitry 212 and tangible elements 214. Electronic circuitry 212 mayinclude RFID circuitry, such as model number MCRF452 available fromMicrochip Technology, Inc., of Chandler, Ariz., transponder circuitry,nanotechnology circuitry, discrete electronic circuitry, analogcircuitry, digital circuitry, processor circuitry, or any othercircuitry. Tangible elements 214 may include batteries, antennas,conductors, holograms, tokens, or any other physical elements.

Donor layers 220 may include one or more suitable materials (e.g.,conductive and non-conductive materials) that are transfer printed ontothe receiver 10 in one or more predetermined patterns. Donor layers 220may reside in a field or region of donor layers on, for example, aribbon (such as ribbon 700 of FIG. 7) before being transfer printed onto receiver 10. During printing, the transfer printing process accordingto the invention precisely transfer prints a predetermined pattern ofthe donor layer residing on the ribbon to the receiver 10. Thus, anypredetermined pattern of donor materials (or combination of donormaterial) may reside on receiver 10. This ability to transfer print apredetermined pattern is somewhat akin to the operation of a typewriter.In a typewriter, a key strike causes a mechanical arm, having a keymember, to strike a ribbon, which contains ink, thereby causing apattern of ink corresponding to the key member to be transferred to apiece of paper. The ink on the paper is analogous to the donor layerresiding on receiver 10.

Donor layers 220 may include different types of material havingdifferent properties. For example, conductive materials, non-conductivematerials, and materials having optical properties may be used. Ifdesired, materials having both conductive and optical properties may beused or materials having both non-conductive and optical properties maybe used. An example of a donor layer 220 that can be used with label 200may include waxes such as paraffin, montan, bees wax, vegetable wax,candeilla wax, polyolefins, polar emulsive polyethylene waxes or othermaterials. Examples of polyethylene waxes are the PED waxes by HoechstAG of Frankfurt, Germany.

Donor layers 220 may include printed elements 222, which are elementsgenerated using the transfer printing process according to theprinciples of the present invention. Printed elements 222, as definedherein, are any elements having a predefined or tangible existence(e.g., physical structure and/or functional existence) that are derivedas a product of transfer printing in accordance with the principles ofthe present invention. That is, printed elements 222 do not have thepredefined or tangible existence until after selective portions of adonor layer are transfer printed to receiver 10. For example, printedelements 222 may exist in a first state before the printing process, butexist in a second, desired, state on label 200 after the printingprocess. More particularly, the composition of printed elements 222 mayexist as a particular layer of ink on the ribbon, but after the printingprocess, a predetermined pattern of the ink layer is transferred fromthe ribbon to receiver 10, thereby rendering printed elements 222 intheir desired, second state. This transition in states is somewhat akinto the transition of ink during operation of a typewriter. That is, theink on the ribbon is in a first state (e.g., a continuous layer of ink)prior to a key strike, but after the key strike, the ink from the ribbonis in a second state (e.g., a letter on the paper). Printed elements222, as they exist on label 200, may include conductors, antennas,insulators, printed paraphernalia, contact nodes (e.g., to enableprogramming and testing of the label or indicia residing thereon), andany other suitable structure.

Substrate 230 may be ubiquitous as to its presence on label 200. Thatis, substrate 230 may include a mixture of materials and components andmay provide a medium through which elements 210 and donor layers 220 maybe fixed to receiver 10. Thus, substrate 230 may function as the“backbone” of label 200, supporting elements 210 and donor layers 220.For example, elements 210 and donor layers 220 may reside on top ofsubstrate 230. Alternatively, substrate 230 may include, for example,adhesive materials for fixing elements 210 to receiver 10, elements 210,donor layers 220, or a combination thereof. In one embodiment, donorlayers 220 (e.g., conductive donor layers and a non-conductive donorlayers) may be transferred to receiver 10 to form substrate 230. In thisembodiment, it will be understood that such a substrate may electricallyinterconnect elements 210 via printed elements 222 that form thesubstrate.

FIG. 3A shows a top view of an embodiment of label 300 that is inaccordance with the principles of the present invention. FIG. 3B shows across-sectional view of label 300 taken along lines A-A in FIG. 3A inaccordance with the principles of the present invention. The followingdiscussion of label 300 is made with reference to both FIGS. 3A and 3B.As shown in the top view, label 300 is disposed on top of receiver 10and includes electronic circuitry 304 (e.g., RFID circuitry), battery306 (e.g., a tangible element), conductor 308, antenna 310, contactspoints 312, conductors 313, and substrate 314. Conductor 308, antenna310, contacts points 312, and conductors 313 are printed elements (e.g.,printed elements 222) that are printed from a donor layer of a source(e.g., a ribbon) and may form part of substrate 314, as shown in thecross-sectional view.

Conductor 308 electrically couples battery 306 to electronic circuitry304. This coupling enables power to be supplied to electronic circuitry304. Conductors 313 electrically couple contact points 312 to electroniccircuitry 304. Antenna 310 is also electrically coupled to electroniccircuitry 304 printed onto receiver 10 in a predetermined pattern suchthat it is electrically coupled to electronic circuitry 304. Antenna 310may be printed in such a way that it is directly coupled to electroniccircuitry 304, thereby avoiding the need to print conductors toelectrically couple electronic circuitry 304 to antenna 310. However, itwill be understood that, if desired, conductors may be printed to coupleantenna 310 to electronic circuitry 304. Contact points 312 are printedat a desired location on receiver 10 and conductors 313 may be printedto electrically couple contact points 312 to electronic circuitry 304.

Referring now to FIG. 3B, substrate 314 generally represents the portionof label 300 that includes conductors 308 and 313, antenna 310, andcontact points 312. Substrate 314 may also include adhesive layer 320,which may be used to affix electronic circuitry 304 to receiver 10.Another adhesive layer (not shown) may be used to affix battery 306 toreceiver 10. Although substrate 314 includes several different elements(e.g., the conductors, antennas, and contact points), not all of theprinted elements are shown to avoid overcrowding the figure. The detailsection of a portion of FIG. 3B taken from circle B, however, does showdifferent regions of substrate 314. For example, regions 322 mayrepresent conductive regions of substrate 314, which includes antenna310, and region 324 may represent a non-conductive region of substrate314. Note the portion of region 322 ext3ending beneath electroniccircuitry 304 may represent an electrical coupling between antenna 310and electronic circuitry 304.

FIG. 4A shows a top view of an embodiment of label 400 that is inaccordance with the principles of the present invention. Label 400 issubstantially similar to label 300 of FIG. 3A. That is, it may includeelectronic circuitry 404, battery 406, conductors 408 and 413, antenna410, contact points 412, and substrate 414. In addition, label 400includes optical readable media. Optical layer 430 may be printed onreceiver 10 and over circuitry, tangible elements, and printed elementsalready affixed to receiver 10. This is shown, for example, in FIG. 4B,which shows a cross-sectional view of label 400 taken along line A-A ofFIG. 4A in accordance with the principles of the present invention.

FIG. 5A shows a top view of an embodiment of label 500 and FIG. 5B showsa cross-sectional view of label 500 taken along line A-A of FIG. 5A inaccordance with the principles of the present invention. The discussionof label 500 will be made with reference to both FIGS. 5A and 5B. Label500 includes electronic circuitry 504, conductors 506, antenna 510,contact points 512, substrate 514 (which includes adhesive regions andconductive and non-conductive regions), and optical layer 530. In thisembodiment, antenna 510 may be a tangible element and not a printedelement as shown in FIGS. 3 and 4. Thus, antenna 510 may reside on topof substrate 514, as shown in FIG. 5B.

The cross-sectional view shows substrate 514 including conductor 506(e.g., a conductive region) and adhesive regions 520. The other regionsof substrate 514 not specifically referred to (e.g., regions other thanregions 506 and adhesive region 520) may include non-conductive regions.Conductor 506 electrically couples antenna 510 to electronic circuitry504 and adhesive regions 520 may affix antenna 510 to receiver 10.Optical layer 530 is shown to be disposed on top of any element uponwhich it resides.

It will be understood that the foregoing discussion of FIGS. 2-5 aremerely illustrative of a few of many different labels that mayconstructed in accordance with the principles of the present invention.For example, indicia having varying spectral emissivity values mayreside on the labels. Such indicia may be read or monitored by detectingtransitions of differential emissitivty on the surface of the label.See, for example, commonly-owned, co-pending U.S. patent applicationSer. Nos. 10/824,975 and 10/973,926, filed Apr. 14, 2004 and Oct. 25,2004, respectively, for more information regarding indicia havingvarying spectral emissivity values and methods and systems for detectingsuch indicia.

Referring now to FIGS. 6-16, embodiments of the present invention thatenable labels according to the invention to be produced are nowdescribed. Generally, ribbons according to the principles of the presentinvention may include elements (e.g., tangible elements) and donorlayers (e.g., printed elements) that are printed onto a receiver. Thus,when a ribbon is placed into, for example, printing machine 5 (of FIG.1), the elements and donor layers retained thereon can be selectivelyprinted on a receiver to provide a desired label.

FIG. 6 shows an illustrative block diagram of a section of ribbon 600according to the principles of the present invention. More particularly,FIG. 6 shows several boxes, which represent different elements andlayers, that may be arranged in predetermined locations on ribbon 600.The elements and layers may or may not overlap each other. The boxes areshown not to overlap to avoid cluttering FIG. 6, but it will beunderstood that one or more of such layers or elements may overlap.

Ribbon 600 may include, but is not limited to, a carrier (not shown), aretaining layer (not shown), elements 602 (e.g., electronic circuitryand tangible elements), conductive layer 604, non-conductive layer 606,guide elements 608, optical layer 610 (or a machine readable or humanreadable medium), and ribbon elements 612. Elements 602 may be elementsfrom which elements 210 (FIG. 2) are derived and layers 604, 606, and610 may be the layers from which donor layers 202 (of FIG. 2) arederived. The carrier provides structural support for ribbon 600,providing a platform for the layers and elements of the ribbon toreside. An appropriate carrier is selected that maintains the layers andelements in their desired locations during printing. The ability tomaintain these desired locations may be necessary to ensure properalignment of the layers and elements as they are printed onto thereceiver. An example of a carrier is MYLAR™ film (biaxially-orientedpolyethylene terephthalate polyester film) having a predeterminedthickness (e.g., 0.010″). Examples of such carriers are films of VitelPolyester PE222 by Goodyear Tire and Rubber Company of Akron, Oh., orMYLAR™ 49000 polyester film by Dupont Corporation of Wilmington, Del.

The carrier may include guide elements 608 that assure properidentification or registration of the layers and elements duringprinting. Guide elements 608 may include holes or punches, magnetic orelectrically conductive materials, or marks that identify or registerparticular regions or fields, layers, and elements of ribbon 600. Guideelements 608 may be “built into” the carrier itself without requiringanything to hold elements 608 in place. For example, if guide elements608 are holes, such holes may be punched directly out of the carrier.Magnetic or electrically conductive materials may form part (e.g., theouter perimeter) of the carrier and may be programmed to indicate whichsections of the ribbon contains particular fields or regions, layers, orelements. Such programming may be akin to writing data on a magnetictape.

Guide elements 608 may be monitored, and based on the monitoring, ribbon600 may be fed (forward or backward or both) to ensure that the layersand elements are accurately printed. If desired, guide elements 608 maybe used to identify regions or fields of ribbon 600. As will bedescribed in more detail below, a particular region may include aparticular layer (e.g., a conductive layer or an optical layer). Forexample, if a printed element such as a conductor requires printing,ribbon 600 may be fed such that a conductive region 604 is in anappropriate position so that the conductor can be printed onto areceiver.

The retaining layer (not shown) retains elements 602 (which may includethe same elements 210 described above in connection with FIG. 2) onribbon 600 until they are affixed to a receiver during printing. Theretaining layer may be, for example, a thermal ink composition or othersuitable material. An example of a retaining layer is Monarch 9446Thermal Transfer manufactured by Monarch Marking Systems of Dayton, Oh.A thermal material may prevent elements 602 from being removed from theribbon until the temperature of the material rises above a predeterminedtemperature. When at temperature, the material “loosens” its grip onelement 602, thereby allowing transfer from the ribbon to the receiver.

Alternatively, the retaining layer may be an adhesive material thatretains element 602 until pressure is applied to cause element 602 to betransferred from the ribbon to the receiver. The adhesive material maybe a wax such as PED waxes by Hoechst AG of Frankfurt, Germany.

Elements 602 may include any element having a predefined or tangibleexistence (e.g., physical structure and/or functional existence) priorto being included on ribbon 600. For example, elements 602 may includecircuitry, batteries, antennas, conductors, holograms, tokens, and otherphysical elements. An adhesive may reside on elements 602 such that whenthe element is printed, the adhesive affixes the element to, forexample, the receiver.

Conductive layer 604 includes a material that is electrically conductiveand has the ability to conduct, for example, electrical signals whenprinted. Conductive layer 604 may be used for printing printed elements(e.g., printed elements 222 discussed above in connection with FIG. 2).For example, conductors that interconnect elements 602 (on the label)may be derived from conductive layer 604. In another example, an antennamay be derived from conductive layer 604.

Conductive layer 604 may be a conductive ink. An example of a conductiveink includes a suspension of an electrically conductive material (e.g.,copper) in a carnauba wax. See, for example, U.S. Patent Application No.US2004/0175515 for an more detailed explanation of a conductive inkcomposition, the disclosure of which is hereby incorporated herein byreference in its entirety.

Non-conductive layer 606 includes a material that is not electricallyconductive. Non-conductive layer 606 may be printed in strategiclocations to prevent, for example, short-circuiting of elements (e.g.,conductive elements and circuitry) on the label. Non-conductive layer606 may include a non-conductive ink composition such as carnauba wax.

Optical layer 610 includes a material for printing conventional orinvisible indicia or marks. For example, optical layer 610 may provide abasis for printing labels. Optical layer 610 may include a conventionalink, such as a carnauba ink, for printing conventional indicia,invisible ink, such as transparent inks that include UV fluorescentmaterials (e.g., zinc cadmium sulfide or gadolinium oxi-sulfide), forprinting invisible indicia, or a combination thereof.

Conductive layer 604, non-conductive layer 606, and optical layer 610may each reside on the ribbon as a region or a field. That is, therespective layers may each occupy a predetermined section of the ribbon.By arranging layers 604, 606, and 610 in regions, the ribbon can bepositioned so that a particular region is properly aligned within theprinting machine, thereby enabling the printing machine to print thecontents of that region.

Ribbon elements 612 include elements known to those skilled in the artto facilitate printing and transfer of layers 604, 606, and 610 to asubstrate (e.g., the receiver). For example, lubricants (e.g., siliconeoil), plasticizers (e.g., di-octyl thalate), and release agents (e.g.,talc) may be incorporated into layers 604, 606, and 610 as ribbonelements 612.

It is understood that while FIG. 6 shows conductive layer 604,non-conductive layer 606, and optical layer 610 as separate layers, thepresent invention is not limited as such. In fact, two or more suchlayers may be combined into the same layer—yielding a multi-purposelayer. Multi-purpose layers may each include materials that can performthe functions of two or more different layers (e.g., a conductive layerand an optical layer). This advantageously provides an economy for useon ribbon 600 (e.g., less space may be required for a multi-purposelayer in contrast to space required for two independent layers).

An example of multi-purpose layer may include a conductive material andan optical material. Thus, when this layer is printed, both conductiveand optical materials may be simultaneously transferred to, for example,a receiver. It will be understood that such a multi-purpose layer can bestrategically printed solely for its optical properties. That is, thelayer may be printed in a location or locations to provide apredetermined mark. In some instances, if such a mark is printed, theconductive properties of the multipurpose layer may “unintentionally”electrically couple, for example, tangible elements 602 (e.g., a batteryto an antenna). This unintentional coupling may be avoided by printing alayer, which includes a non-conductive optical material, in place of theportion of the mark where the electrical coupling is undesired, therebyenabling the desired mark to be printed while at the same timepreventing the undesired electrical coupling.

An advantage of the ribbon according to the present invention is that itprovides substantial flexibility in the design, layout, and compositionof the elements and layers provided thereon. Thus, ribbon 600, forexample, may be constructed to fulfill any predetermined criteria. Forexample, ribbon 600 may be constructed to promote the ease in which aprinting machine may print selected elements and layers onto, forexample, a receiver to provide a predetermined label. In fact, as willbe described in more detail in connection with the text accompanyingFIGS. 7-11, there is a relationship between the layout of the ribbon andits interaction with a printing machine.

It is understood that FIG. 6 is merely illustrative and that additionalelements or layers may be added to ribbon 600, and that elements orlayers may be omitted. For example, in FIG. 6, optical layer 610 may beomitted.

FIG. 7A shows a top view of an embodiment of ribbon 700 in accordancewith the principles of the present invention. More particularly, FIG. 7Ashows a section of ribbon 700 that includes elements and layers forprinting three separate labels. For brevity and clarity, and to avoidovercrowding FIG. 7A and FIG. 7B (discussed below), the elements andlayers of only one sub-section (i.e., the center sub-section) of ribbon700 are labeled. As shown in FIG. 7A, ribbon 700 includes guide elements704, RFID circuitry 710, conductive layer 712, non-conductive layer 714,and optical layer 716. RFID circuitry 710, may reside in region 720 ofribbon 700, layer 712 in region 722, and layers 714 and in region 724.

FIG. 7B shows a cross-sectional view of ribbon 700 taken along the lineA-A of FIG. 7A in accordance with the principles of the presentinvention. The cross-sectional view shows that ribbon 700 includescarrier 702 and adhesive layer 711, in addition to RFID circuitry 710,layer 712, and layer 714. As shown, adhesive layer 711 may reside on topof RFID circuitry 710.

FIG. 8 shows a perspective view of an embodiment of a ribbon assembly800 that is in accordance with the principles of the present invention.Ribbon assembly 800 may serve as a “cartridge” that can be inserted intoa printing machine for printing indicia according to the presentinvention. As shown, assembly 800 includes feeder roll 802, forsupplying a ribbon including predetermined elements and layers, andtake-up roll 804, for retrieving the ribbon after printing.

As shown in FIG. 8, the ribbon includes carrier 812, guide elements 814,RFID circuitry 816, battery 818, antenna 820, and regions 822 and 824.In this embodiment, guide elements 814 are shown as punched holes andcircuitry 816, battery 818, and antenna 820 are shown as physicalelements (e.g., tangible elements) that can be transferred from theribbon to a substrate (e.g., receiver). Region 822 may include one ormore predetermined thermal transfer materials. For example, region 822may include a conductive ink, an optical ink, or a mixture of bothoptical and conductive ink. Region 824 illustrates that a region mayinclude elements, such as antenna 820, and a layer of thermal transfermaterial. Though not shown in FIG. 8, another region may includecircuitry 816 and battery 818.

If ribbon assembly 800 or ribbon 700 (of FIG. 7) is used for generatinglabels according to the present invention, the elements and layers maybe placed face down so that application of a printing means (e.g., aheat transfer element) results in a substantially direct transfer of theelement or layer from the ribbon to, for example, a receiver. Forreference, in FIGS. 7 and 8, the elements and layers are shown face up.

FIG. 9 shows a block diagram of a printing system 900, such as printingsystem 5 (of FIG. 1), that is in accordance with the principles of thepresent invention. Printing system 900 may include an input source 902,display device 904, storage device 906, control circuitry 908, andprinting machine 910. Control circuitry 908 may include a processor andother circuitry (e.g., circuitry for controlling specific functions ofprinting machine 910) based on data received from input source 902,storage device 906 (e.g., memory or a database), and printing machine910 (e.g., sensors). In addition, control circuitry 908 is operable tocontrol the flow of data between control circuitry 908 and printingmachine 910, and control circuitry 908 and storage device 906, asevidenced by bi-directional communications path 909. Further, controlcircuitry 908 may provide data to display device so that informationpertaining to, for example, the operation of system 900 can bedisplayed.

Input source 902 may include any source from which data can be providedto control the operation of control circuitry 908 to generatepredetermined labels. For example, source 902 may include a local inputsource (e.g., a keypad, keyboard, or computer attached to system 900)that enables a user or computer (operating according to programmedprotocols) to specify desired parameters for labels being produced bysystem 900. Local source 902 may reside within or on the body of thesystem 900. As another example, source 902 may include a remote source(e.g., a control center that is interfaced with system 900 via anetwork) that enables a user or computer to remotely specify desiredparameters for labels being produced by system 900. The remote sourcemay transmit data to control circuitry 908 via a hard-wired connection(e.g., a cable), a wireless connection (e.g., infrared, Bluetooth™,broadband wireless connection, etc.) or other remote source technology.It is understood that while the foregoing mentions a couple examples ofinput sources, the present invention may be practiced using anyconventional device (e.g., keyboard or mouse) or system (e.g., computeror control center) may be used, therefore a detailed discussion of suchinput sources is not necessary.

Storage device 906 may include one or more devices capable of storingdata. For example, storage device may include volatile memory (e.g.,RAM, SDRAM, flash memory, etc.), non-volatile memory (e.g., ROM),digital storage devices (e.g., a hard-drive, a tape backup drive, or anoptical drive for reading data from and writing data to disks). Storagedevice 906 may be controlled by control circuitry 908. For example,control circuitry 908 may cause data to be stored on storage device 906and may retrieve data from storage device 906. Data stored in storagedevice 906 may include programs that are implemented by controlcircuitry 908 to instruct printing machine 910 to print labels andperforming other operations (e.g., testing and programming the labels orindicia residing thereon) in connection with printing machine 910.

Control circuitry 908 generally operates to coordinate the interactionand operation of the components of system 900. For example, controlcircuitry 908 may be responsive to inputs received from input source 902and storage device 906 to control the operation of printing machine 910.Control circuitry 908 may run software that is loaded onto, for example,storage device 906, transmit signals to various components of printingmachine 910, and utilize any technology available for operating system900 in accordance with the principles of the present invention.

In addition, control circuitry 908 may provide signals to display device904 for displaying information. For example, information indicating thenumber of labels that have been printed (e.g., batch count), theavailable quantities of material (e.g., ribbon) available for printinglabels, the characteristics of the labels being printed, operationalstatus (e.g., fault error), or any other information. If desired,information may be displayed in response to commands received from inputsource 902, storage device 906, or a combination thereof.

Printing machine 910 may be any machine capable of printing labels inaccordance with the principles of the present invention. Thus, printingmachine 910, operating under the direction of control circuitry 908, mayprint labels on demand. That is, printing machine 910 may print a firstlabel according to a first predetermined set of parameters andsubsequently print a second label according to a second set ofparameters without requiring any retooling or reconfiguring of themachine. Advantageously, rather than retooling or reconfiguring themachine, control circuitry 908 can provide the appropriate signals (inresponse to received inputs from input source 902 or storage device 906)to cause printing machine 910 to print a predetermined label.

In addition to printing predetermined labels, printing machine 910 mayalso be able to program and test the label, or indicia thereof. Forexample, printing machine 910 may program electronic circuitry (e.g.,RFID circuitry) before, after, or while it is being printed onto areceiver. This programming ability further adds to the on demand labelproduction capabilities of printing system 900. Moreover, the testingcapabilities enables printing system 900 to verify whether a particularlabel operates properly, thereby providing a means for preventingdefective labels from being used. The programming and testing may beperformed under the direction of control circuitry 908.

FIG. 10 shows another block diagram of a printing system 1000 that is inaccordance with the principles of the present invention. Printing system1000 includes components discussed above in connection with printingsystem 900, but printing system 1000 illustrates a more detailedembodiment of system 900. For example, printing system 1000 includesinput source 1002, display device 1004, storage devices 1006, controlcircuitry 1008, printing machine 1010, and network 1011. Note thatcomponents 10XX in FIG. 10 are similar to and may perform the samefunctions as components 9XX of FIG. 9. Persons skilled in the art willappreciate that, in various embodiments of the present invention,similar or identical components may be utilized to perform similar oridentical functions. Therefore, the foregoing discussion with respect tocomponents 9XX also applies to components 10XX.

A difference between FIG. 9 and FIG. 10 is that FIG. 10 illustratesexamples of components or subsystems that may be included in storagedevices 1006, control circuitry 1008, and printing machine 1010. Asshown in FIG. 10, storage device 1006 includes database 1006A and memory1006B, control circuitry 1008 includes a processor 1020, test/programcontroller 1030, print controller 1040, ribbon controller 1050, andreceiver controller 1060, and printing machine 1010 includestest/program device 1032, thermal transfer device 1042, pressuretransfer device 1044, guide element sensors 1052, ribbon drive unit1054, and receiver drive unit 1062.

Storage device 1006, control circuitry 1008, are shown to be containedin dashed-line boxes to indicate that the arrangement of the componentsand subsystems contained therein are merely illustrative. For example,as an alternative arrangement, memory 1006B may be included withincontrol circuitry 1008, instead of being included as part of storagedevice 1006. As a further alternative embodiment, test/programcontroller 1030, print controller 1040, ribbon controller 1050, receivercontroller 1060, or a combination thereof may be included as part ofprinting machine 1010, rather than part of control circuitry 1008.

Processor 1020 may be any conventional processor capable of performingdata processing functions of control circuitry 1008. Processor 1020 mayreceive data from and transmit data to storage device 1006, network1011, test/program controller 1030, print controller 1040, ribboncontroller 1050, and receiver controller 1060. Bi-directionalcommunication lines 1022 may be provided to enable such bi-directionaltransfer of data. In addition, processor 1020 may transmit data todisplay device 1004 and receive data from input source 1002.

During operation of printing system 1000, processor communicates withcontrollers 1030, 1040, 1050, and 1060 to generate labels on demand.Controllers 1030, 1040, 1050, and 1060 may each include circuitry toperform specific control functions. For example, test/program controller1030 may be operative to control test/program device 1032. Similarly,print controller 1040 may be operative to control thermal transferdevice 1042 and pressure transfer device 1044; ribbon controller may beoperative to control guide element sensors 1052 and ribbon drive unit1054; and receiver controller 1060 may be operative to control receiverdrive unit 1062. Thus, it is understood that the operation of thecomponents in printing machine 1010 (e.g., thermal transfer device 1042)are controlled by processor 1020 by via the appropriate controller(e.g., print controller 1040), and, that by virtue of this control, dataprovided to processor (from input source 1002, storage device 1006, andnetwork 1011) can instruct processor to generate a predetermined labelon demand.

Referring now to both FIGS. 10 and 11, a method of using printing system10 is described to illustrate how labels may be generated according tothe invention. FIG. 11 shows a diagrammatic view of sections of printingsystem 1000 and other components not shown in FIG. 10 in accordance withthe principles of the present invention. Ribbon 1070 (e.g., ribbon 600of FIG. 6) is supplied by a ribbon supply roll 1055 and taken up bytake-up roll 1056. The combination of ribbon 1070, supply roll 1055, andtake-up roll 1056 may constitute an assembly similar to ribbon assembly800 discussed above in connection with FIG. 8. Tension elements 1072 mayassist supply roll 1055 and take-up roll 1056 in holding ribbon 1070taut as it passes from supply roll 1055 to take-up roll 1056. Otherelements (not shown) may be provided to prevent torsion or twisting ofribbon 1070. A taut ribbon 1070 may promote printing accuracy ofelements (e.g., circuitry, antennas, batteries, etc.) and layers (e.g.,conductive ink, optical ink, etc.) onto receiver 1080.

Ribbon drive unit 1054 which may include one or more conventional motors(e.g., DC motor, AC motor, induction motor, etc.), may control the rateand directions in which ribbon 1070 is transported through printingmachine 1010. As shown in FIG. 11, drive unit 1054 is coupled to take-uproll 1056 and operates the rotate roll 1056 at a predetermined speed orrange of speeds to draw ribbons from supply roll 1055. Because driveunit is shown being coupled to first take-up roll 1056, the ribbon maytravel in one direction (e.g., right-to-left). As an alternative, driveunit 1054 may, also be coupled to supply roll 1056, thereby enablingribbon 1070 to move in both directions (e.g., left-to-right andright-to-left). Regardless of which embodiment is implemented, ribbondriver unit 1054 may operate in connection with guide element sensors1052. That is, guide element sensors 1052 may transmit data indicativeof the position of ribbons 1070 to control circuits 1008, (moreparticularly, ribbon controls 1050), which may then transmit theappropriate signals to control the operation of drive unit 1054. Toposition ribbon 1070 in a predetermined position with respect to thermaltransfers device 1042 or pressure transfer device 1044. When ribbon 1070is positioned in a predetermined position, signals may be transmittedfrom control circuitry 1008 to thermal transfer device 1042 or pressuretransfer device 1044 to cause selected portions of ribbon 1070 to betransferred to receiver 1080.

Guide element sensors 1052 may be any device capable of detecting guideelements such as guide elements 704 of FIGS. 7 and 814 of FIG. 8. It isunderstood that sensors 1052 may be selected to detect the specificguide elements contained on ribbons 1070. For example, if the guideelements are magnetic devices, sensors 1052 preferably are able todetect magnetic signals. As another example, if guide elements areholes, sensors 1052 may be optical sensors for detecting the presence ofsuch holes.

Thermal transfer device 1042 may be any device responsive to commandsprovided by control circuitry 1008 or, more particularly, printcontroller 1040, to thermally transfer selective portions of ribbon 1070to receiver 1080. Thermal transfer device 1042 preferably thermaltransfers, for example, layers residing on ribbon 1070 (e.g., aconductive link layer) to receiver 1080 without chemically altering thelayer (like the way conventional ink jet technology chemically altersink). This is accomplished by thermally transferring the layer toreceiver 1080. That is, a plurality of elements (not shown) in device1042 may be selectively heated to effect transfer of a predeterminedpattern of a donor layer to receiver 1080. The heating elements mayinclude, for example, resistors, transistors such as thin-filmtransistors, or other heat-bearing elements. Thermal transfer device1042 may be sufficiently sized such that it can transfer any portion ofthe donor layer. For example, considering ribbon 700 of FIG. 7 as anexample, device 1042 may be constructed such that it can transfer anyportion across the entire width of layer 712 to receive 1080. Thisapproach enables transfer device 1042 to quickly and accurately transferdonor layer without requiring device 1042 to be positioned in anappropriate position to effect desired heat transfer.

In an alternative approach, thermal transfer device 1042 may be movedhorizontally with respect to ribbon 1070 in order to position itproperly to effect desired heat transfer. For example, referring againto ribbon 700 of FIG. 7, when region 724 is positioned under device1042, device 1042 may be moved horizontally across width of ribbon 700such that in a first position, it may be positioned over layer 714, andin a second position, it may be positioned over layer 716.

As a further alternative embodiment, two or more thermal transferdevices may be used to effect thermal transfer in accordance with theinvention. For example, multiple thermal transfer devices may be arrayedin parallel or may be arranged in a staggered parallel fashion.

Pressure transfer device 1044 may be any device responsive to commandsprovided by control circuitry 1008 or, more particularly, printcontroller 1040 to transfer through applications of a predeterminedpressure selective portions of ribbon 1070 to receiver 1080. Pressuretransfer device 1044 may transfer elements (e.g., circuitry, batteries,antennas, etc.) by selectively lowering roller 1045 onto ribbon 1070.Roller 1045 preferably contacts ribbon with sufficient (e.g., whether itis an element or an adhesive layer) force to cause whichever portion ofribbon 1070 it contacts to be transferred to receiver 1080. Rollercontrol device 1046, which may be a solenoid, may lower and raise roller1045 as needed to effect pressure transfer. In particular, roller 1045may contact the carrier (e.g., carrier 702 of ribbon 700) portion ofribbon 1070.

If desired, two or more rollers may be used to selectively applypressure to ribbon 1070. For example, the plurality of rollers may bearrayed in parallel or staggered according to predetermined designcriteria.

Although FIG. 11 shows thermal transfer device 1042 and pressuretransfer device 1044 as two independent units, those of skill in the artwill appreciate that the functionality of both devices may be combinedinto a single device in the case where contact pressure of and heat fromthe thermal transfer device is sufficient to release components from thecarrier and bond them on the substrate. Receiver 1080 is selectively fedthrough printing machine 1010 by receiver drive unit 1062, which isresponsive to signals provided by control circuitry 1008. Receiver driveunit 1062 feeds receiver 1080 over support 1064 and support rollers 1066to support 1038. Control circuitry 1008 may coordinate the advance ofreceiver 1080 in connection with the advance of ribbon 1070 to ensureconcomitant printing.

As ribbon 1070 is initially fed from supply roll 1055, the carrier endof the ribbon is faced towards guide element sensors 1052, pressuretransfer device 1044 and thermal transfer device 1042, and the donorlayers and elements are faced towards receiver 1080. Under the controlof signals provided by control circuitry 1008, transfer devices 1042 and1044 may transfer donor layers and elements to receiver 1080. Theprinted portion of ribbon 1070 is then taken up by take-up roll 1056.

Test/program device 1032 is responsive to control signals to test and/orprogram labels being generated in printing machine 1010. For example,test/program device 1032 may cause an RFID device to transmit itspredetermined data, whether printed conductors have properlyelectrically coupled various elements, or whether the printed markconforms with predetermined specifications. To perform testing and/orprogramming, probe 1033 may be lowered and raised as necessary bymechanism 1034 to make contact with test probe points on the labelresiding on support 1038.

Although FIG. 11 shows test/program device 1032 positioned to test andprogram labels or indicia thereof after it has been generated, it isunderstood that testing and programming may be performed in any stage(e.g., before, during, or after printing) of the printing process. Forexample, elements such as electronic circuitry (e.g., RFID circuitry)may be programmed on ribbon 1070 prior to being transferred to receiver1080. After such element has been transferred to receiver 1080, it maybe tested.

FIGS. 12-15 shows several flowcharts illustrating various processes thatmay be performed using system 1000. Accordingly, reference to variouscomponents of system 1000 may be made in connection with the discussioncorresponding to FIGS. 12-15.

FIG. 12 shows a flowchart illustrating a process for printing labels inaccordance with the principles of the present invention. Starting atstep 1210, printing system 1000 may receive data that defines the labelto be produced. Control circuitry 1008 may use this data to generate andprovide the appropriate control signals to various components ofprinting system 1000 to produce the desired label. At step 1220, aribbon is provided. The ribbon is fed to a predetermined position, asindicated at step 1230. For example, the ribbon may be fed in responseto control signals provided by control circuitry 1008. Referring now toFIG. 13, FIG. 13 illustrates steps that may be performed to feed theribbon to a predetermined position. At step 1232, the position of theribbon may be monitored. Such monitoring may be performed by guideelement sensors 1052. At step 1234, the position of the ribbon may beforward advanced based on the monitored position. Optionally, at step1236, the position of the ribbon may be reverse advanced based on themonitored position. Thus, the ribbon may be advanced (e.g., forward orreversed advanced) as needed such that an appropriate region of theribbon is properly aligned, for example, with respect to a transferdevice (e.g., thermal transfer device 1042 or pressure transfer device1044).

Referring back to FIG. 12, at step 1240, the process may selectivelytransfer portions of the ribbon to a receiver at the predeterminedposition. FIG. 14 shows illustrative steps that may be performed at step1240. For example, at step 1242, pressure may be applied to the ribbonto transfer a selected portion of the ribbon to the receiver. At step1244, a selected portion of the ribbon may be thermally transferred tothe ribbon. Returning back to FIG. 12, at step 1250, a determination ismade as to whether printing is complete—that is, all indicia forming thelabel have been transferred to the receiver. Assuming that printing isnot complete, the process may loop back to step 1230. Assuming thatprinting is complete, the process may end.

Persons skilled in the art will appreciate that the steps shown in FIGS.12, 13, and 14 are merely illustrative and that additional steps may beadded or steps may be omitted. For example, steps for feeding thereceiver or testing operation of the label or indicia therof may beadded. As another example, step 1236 (of FIG. 13) may be omitted.

FIG. 15 shows another flowchart illustrating a process for printingindicia in accordance with the principles of the present invention. Theprocess shown in FIG. 15 is similar to that shown in FIG. 12, but showswith more particularity an embodiment that may be practiced by thepresent invention. Beginning at step 1502, a receiver is provided. Thereceiver may be driven by receiver drive unit 1062 according to controlsignals provided by, for example, control circuitry 1008. At step 1504,a ribbon including at least one element (e.g., RFID circuitry, battery,antenna, etc.) and at least one donor layer (e.g., conductive ink layer,optical ink layer, etc.) may be provided. The ribbon may be driven byribbon drive unit 1054 according to control signals provided by, forexample, control circuitry 1008. In fact, ribbon drive unit 1054 andreceiver drive unit 1062 may coordinate the feed of the ribbon and thereceiver, respectively, to ensure proper printing. At step 1506, theribbon may be fed to a predetermined position and at step 1508, thereceiver may be fed to a predetermined position. Steps 1506 and 1508 areshown side-by-side to illustrate that the ribbon and the receiver may besimultaneously fed. Though, those of skill in the art will appreciatethat that the ribbon and the receiver may be fed independent each other.For example, there may be instances where the ribbon is advanced, butnot the receiver. This may occur, for example, when multiple layersand/or elements are being printed onto the same location on thereceiver.

The process may advance to either one or both of steps 1510 and 1512,depending on which portions of the ribbon require printing at a givenpredetermined position of the ribbon and/or the receiver. At step 1510,at least one element (e.g., RFID circuitry or battery) of the ribbon maybe transferred to the receiver. At step 1512, a portion of at least onedonor layer may be transferred to the receiver. Any suitable means maybe employed to effect transfer of the element or donor layer to thereceiver. In a preferred embodiment, however, elements may betransferred by a pressure transfer device (e.g., pressure transferdevice 1044) and donor layers may be transferred by a thermal transferdevice (e.g., thermal transfer device 1042). The transfer of elementsand donor layers may occur simultaneously or independently of eachother.

At step 1514, a determination is made as to whether printing iscomplete. If printing is not complete, the process loops back to steps1506 and 1508 to enable further feeding of the ribbon and/or receiverand transferring of elements or donor layers or both. If printing iscomplete, the process may proceed to step 1516, where at least one ofthe elements (e.g., RFID circuitry) may be programmed. For example, anelement such as RFID circuitry may be programmed to emit predetermineddata fit for the purpose for which the label is used. At step 1518,testing may be performed. The testing may include determining whether aparticular element (e.g., RFID circuitry or battery) operates properlyor whether the label operates properly.

It is understood that the steps shown in FIG. 15 are merely illustrativeand that the order in which certain steps are executed may berearranged, that steps may be added, and that steps may be omitted. Forexample, programming step 1516 may be executed before the programmableelement is transferred to the receiver at step 1510. Moreover, testingof, for example, the programmable element may also be performed prior tobeing transferred to the receiver.

FIG. 16 shows a flowchart illustrating a process for programming aprogrammable element in accordance with the principles of the presentinvention. Programming of a programmable element or circuitry (e.g.,RFID circuitry) may occur at any point in the process for producinglabels in accordance with the invention. For example, programming mayoccur before, during, or after the element or circuitry is transferredto the receiver. Regardless of when the programmable element isprogrammed, the process for programming the element may start at step1602 by electrically coupling a probe to a programmable element. Thecoupling may be any coupling capable of transmitting signals to theprogrammable element, as shown in step 1604. For example, the couplingmay be a physical connection or a wireless connection. At step 1606, theprogrammable element is programmed with the transmitted signals.

Another aspect of the invention is that tests may be performed at anypoint during the label printing process. For example, testing may occurbefore, during, or after the element or circuitry is transferred to thereceiver. Testing can verify, for example, whether the label operatesproperly. Such a test may monitor the RF signal emitted by the label anddetermine whether the RF signal includes data that meets predeterminedcriteria. If the label actively emits a radio frequency signal (becauseit may be powered by a battery), testing may be accomplished bymonitoring the radio signal. If the label passively emits a radio signalin response to an activation signal, testing of such a label may includethe transmission of that activation signal to incite emission of thelabel's radio signal and monitoring of the radio signal.

Another test may be performed to ensure that physical connections,resulting from the printing of conductive donor layers, between elementsare satisfactory. Such tests may determine whether an antenna isconnected to the RFID circuitry or whether a battery is connected to theRFID circuitry. Other tests may be performed to verify whether eachelement is functioning properly. The testing of individual elements maybe performed while the element resides on the ribbon or when the elementhas been transferred to a receiver.

Testing may be performed through the use of a probe that may or may notbe physically coupled to the label or indicia. For example, a probe suchas probe 1033 of FIG. 11 may be used to perform tests in accordance withthe principles of the invention.

Thus it is seen that customizable labels having electronic circuitry canbe produced using the systems and methods according the presentinvention. A person skilled in the art will appreciate that the presentinvention can be practiced by other than the described embodiments,which are presented for purposes of illustration rather than oflimitation, and the present invention is limited only by the claimswhich follow.

1. A method for printing indicia onto a receiver, comprising:controlling feed of a ribbon through a printing system, the ribboncomprising indicia, at least one of the indicia comprising programmablecircuitry; selectively transfer printing the indicia from the ribbon tothe receiver; and programming the programmable circuitry.
 2. The methodof claim 1, wherein the controlling comprises: advancing the ribbon to apredetermined position.
 3. The method of claim 1, wherein thecontrolling comprises: monitoring guide elements located on the ribbon.4. The method of claim 3, further comprising: coordinating feed of thereceiver in connection with the feed of the ribbon.
 5. The method ofclaim 1, further comprising: receiving data that defines how the indiciais to be printed on the receiver, wherein the controlling and theprinting are executed based on the data.
 6. The method of claim 1, theindicia comprising: at least one element.
 7. The method of claim 6,wherein the at least one element comprises circuitry.
 8. The method ofclaim 6, wherein the at least one element comprises a power source. 9.The method of claim 6, wherein the at least one element comprises anantenna.
 10. The method of claim 6, wherein the at least one elementcomprises radio frequency identification circuitry.
 11. The method ofclaim 1, wherein the indicia comprises at least one donor layer.
 12. Themethod of claim 11, wherein the at least one donor layer comprises aconductive material.
 13. The method of claim 11, wherein the at leastone donor layer comprises a non-conductive material.
 14. The method ofclaim 11, wherein the at least one donor layer comprises an opticalmaterial.
 15. The method of claim 1, wherein the transfer printingcomprises thermal transfer printing.
 16. The method of claim 1, whereinthe transfer printing comprises pressure transfer printing.
 17. Themethod of claim 1, further comprising: testing at least one indicium.18. A method for generating a label, comprising: providing a ribboncomprising a plurality of donor layers and a plurality of elements; andselectively transfer printing from the ribbon onto a receiver a portionof at least one of the donor layers and at least one of the elements.19. The method of claim 18, wherein at least one of the elementscomprises a power source.
 20. The method of claim 18, wherein thetransfer printing comprises pressure transfer printing.
 21. The methodof claim 18, wherein the printed portion comprises an antenna.
 22. Themethod of claim 18, wherein the printed portion comprises a conductor.23. The method of claim 18, wherein the printed portion comprises a testnode.
 24. The method of claim 18, wherein the printed portion comprisesmachine-readable indicia.
 25. The method of claim 18, wherein theprinted portion comprises a human-readable indicia.
 26. The method ofclaim 18, wherein the transfer printing comprises: electrically couplingat least one of the elements with the printed portion.
 27. The method ofclaim 18, wherein the transfer printing comprises: electrically couplinga first transfer printed element and a second transfer printed elementwith the printed portion.
 28. The method of claim 18, wherein theportion is a first portion, and wherein the transfer printing comprises:printing the first portion before printing the at least one element. 29.The method of claim 28, further comprising: transfer printing a secondportion of at least one of the donor layers after the first portion isprinted.
 30. The method of claim 29, wherein the second portion isprinted on top of the at least one element and first portion.
 31. Themethod of claim 18, wherein at least one of the donor layers comprises apredetermined ink.
 32. The method of claim 31, wherein the predeterminedink is selected from a group consisting of a conductive ink, anon-conductive ink, an optical ink, or a combination thereof.
 33. Themethod of claim 18, wherein at least one of the elements comprisesprogrammable circuitry.
 34. The method of claim 18, wherein at least oneof the elements comprises radio frequency identification circuitry. 35.The method of claim 18, wherein at least one of the elements comprisesan antenna.
 36. The method of claim 18, further comprising: programmingat least one of the elements.
 37. The method of claim 36, wherein theprogramming is performed before, during, or after the element istransfer printed to the receiver.
 38. The method of claim 18, furthercomprising: testing at least one of the elements.
 39. The method ofclaim 38, wherein the testing is performed before, during, or after theelement is transfer printed to the receiver.
 40. The method of claim 18,wherein the transfer printing comprises thermal transfer printing. 41.The method defined in claim 40, further comprising: receiving data thatdefines the label is to be printed; and generating control signals basedon the data to control the selective transfer printing.
 42. The methodof claim 41, wherein the received data is proved in response to a userinput.
 43. The method of claim 41, further comprising: using the controlsignals to control a feed of the ribbon.
 44. The method of claim 42,further comprising: using the control signals to control a feed of thereceiver.
 45. A method for generating labels using a printing systemthat includes a ribbon comprising a conductive ink layer and radiofrequency identification (RFID) circuitry, the method comprising:monitoring the position of the ribbon; selectively feeding the ribbonbased on the monitored position; transfer printing the RFID circuitryand conductive ink from the ribbon when the ribbon is fed to one or morepredetermined positions; and programming the RFID circuitry.
 46. Themethod of claim 45, wherein the RFID circuitry and the conductive inkare transfer printed to a receiver.
 47. The method of claim 45, furthercomprising: testing the RFID circuitry.
 48. The method of claim 45,wherein the transfer printing comprises: using a pressure transferdevice to transfer print the RFID circuitry.
 49. The method of claim 45,wherein the transfer printing comprises: using a thermal transfer deviceto transfer print the conductive ink.
 50. The method of claim 45,wherein the transfer printing comprises: printing an antenna from theconductive ink; and electrically coupling the RFID circuitry and theantenna with the conductive ink.
 51. The method of claim 45, wherein theribbon further comprises a power source, the method further comprising:transfer printing the power source when the ribbon is fed to one of thepredetermined positions, wherein the conductive ink is transfer printedto electrically couple the power source and the RFID circuitry.
 52. Themethod of claim 45, further comprising: providing control signals,wherein the control signals control the feed of the ribbon, the transferprinting, and the programming.
 53. A method for producing a label ondemand, comprising: feeding a ribbon through a printing system;thermally transferring a first portion of the ribbon to a receiver; andapplying pressure to a second portion of the ribbon to transfer anelement from the ribbon to the receiver.
 54. A method for producing aradio frequency identification (RFID) tag, comprising: providing aribbon comprising RFID circuitry and conductive ink; and printing theRFID circuitry and the conductive ink from the ribbon onto a receiversuch that an antenna, which is printed on the receiver from theconductive ink, is electrically coupled to the RFID circuitry by theconductive ink.
 55. A method for producing labels, comprising: providinga ribbon comprising elements and a conductive donor layer; transferringthe elements from the ribbon to a receiver; and selectively transferringthe conductive donor layer to the receiver to electrically couplepredetermined transferred elements to each other.
 56. The method ofclaim 55, wherein said ribbon further comprises an optical donor layer,said method further comprising: transferring said optical layer to saidreceiver.
 57. A printing system for generating a at least one label ondemand, comprising: control circuitry; and printing apparatuselectrically coupled to and controlled by the control circuitry, theprinting apparatus comprising: a receiver drive unit for feeding areceiver through the printing system; a ribbon drive unit for feeding aribbon that includes electronic circuitry through the printing system;at least one print transfer device for transfer printing the electroniccircuitry from the ribbon to the receiver; and a programming device forprogramming the electronic circuitry.
 58. The system of claim 57,wherein the printing apparatus further comprises: at least one guideelement sensor that monitors guide elements located on the ribbon. 59.The system of claim 57, wherein the at least one print transfer devicecomprises a thermal transfer print device that thermally transfers aportion of the ribbon to the receiver.
 60. The system of claim 57,wherein the at least one print transfer device comprises a pressuretransfer print device that applies pressure to a portion of the ribbonto cause that portion to be pressure transferred to the receiver. 61.The system of claim 57, wherein the controller comprises a receivercontroller electrically coupled to and operative to control the receiverdrive unit, thereby controlling the feed of the receiver.
 62. The systemof claim 57, wherein the controller comprises a ribbon controllerelectrically coupled to and operative to control the ribbon drive unit,thereby controlling the feed of the ribbon.
 63. The system of claim 57,wherein the controller comprises a print controller communicativelycoupled to and operative to control the at least one print transferdevice.
 64. The system of claim 57, wherein the controller comprises aribbon controller communicatively coupled to and operative to controlthe ribbon drive unit and the at least one guide element sensor.
 65. Thesystem of claim 57, wherein the programming device is further operativeto test the label.
 66. The system of claim 57, further comprising atleast one storage device communicatively coupled to the controlcircuitry, the storage device having data stored therein that providesinstructions to the control circuitry for generating the label ondemand.
 67. The system of claim 57, further comprising at least oneinput source communicatively coupled to the control circuitry.
 68. Thesystem of claim 57, wherein the ribbon comprises indicia that isselectively transfer printed to the receiver by the at least one printtransfer device.
 69. The system of claim 68, the indicia comprising: atleast one element; and at least one donor layer.
 70. The system of claim69, wherein the at least element comprises radio frequencyidentification circuitry.
 71. The system of claim 69, wherein the atleast one element comprises programmable circuitry.
 72. The system ofclaim 69, wherein the at least one element comprises a power source. 73.The system of claim 69, wherein the at least one element comprises anantenna.
 74. The system of claim 69, wherein the at least one donorlayer comprises a conductive material.
 75. The system of claim 69,wherein the at least one donor layer comprises a non-conductivematerial.
 76. The system of claim 69, wherein the at least one donorlayer comprises an optical material.
 77. The system of claim 57 iscontained within a portable housing.
 78. A system for printing indiciaonto a receiver, the system comprising a printing apparatus operativeto: control feed of a ribbon comprising indicia, at least one of theindicia comprising programmable circuitry; selectively transfer printthe indicia from the ribbon to the receiver; and program theprogrammable circuitry.
 79. The system of claim 78, wherein the printingapparatus is operative to: monitor guide elements located on the ribbon;and advance the ribbon to a predetermined position based on themonitored guide elements.
 80. The system of claim 79, wherein theprinting apparatus is operative to: coordinate feed of the receiver inconnection with the feed of the ribbon.
 81. The system of claim 78,wherein the printing apparatus is operative to: receive data thatdefines how the indicia is to be printed on the receiver; and print theindicia based on the received data.
 82. The system of claim 78, theindicia comprising: at least one element.
 83. The system of claim 82,wherein the at least one element comprises circuitry.
 84. The system ofclaim 82, wherein the at least one element comprises a power source. 85.The system of claim 82, wherein the at least one element comprises anantenna.
 86. The system of claim 82, wherein the at least one elementcomprises radio frequency identification circuitry.
 87. The system ofclaim 78, wherein the indicia comprises at least one donor layer. 88.The system of claim 87, wherein the at least one donor layer comprises aconductive material.
 89. The system of claim 87, wherein the at leastone donor layer comprises a non-conductive material.
 90. The system ofclaim 87, wherein the at least one donor layer comprises an opticalmaterial.
 91. The system of claim 78, wherein the printing apparatus isoperative to: thermal transfer print the indicia to the receiver. 92.The system of claim 78, wherein the printing apparatus is operative to:pressure transfer print the indicia to the receiver.
 93. The method ofclaim 78, wherein the printing apparatus is operative to: test at leastone indicium.
 94. A system for generating a least one label, the systemcomprising a printing apparatus that uses a ribbon comprising aconductive ink layer and radio frequency identification (RFID)circuitry, the printing apparatus operative to: monitor the position ofthe ribbon; selectively feed the ribbon based on the monitored position;transfer print the RFID circuitry and conductive ink from the ribbonwhen the ribbon is fed to one or more predetermined positions; andprogram the RFID circuitry.
 95. The system of claim 94, wherein the RFIDcircuitry and the conductive ink are transfer printed to a receiver. 96.The method of claim 94, wherein the printing apparatus is operative to:test the RFID circuitry.
 97. The system of claim 94, wherein theprinting apparatus is operative to: use a pressure transfer device totransfer print the RFID circuitry.
 98. The system of claim 94, whereinthe printing apparatus is operative to: use a thermal transfer device totransfer print the conductive ink.
 99. The system of claim 94, whereinthe printing apparatus is operative to: print an antenna from theconductive ink; and electrically couple the RFID circuitry and theantenna with the conductive ink.
 100. The system of claim 94, whereinthe ribbon further comprises a power source, the printing apparatus:transfer print the power source when the ribbon is fed to one of thepredetermined positions, wherein the conductive ink is transfer printedto electrically couple the power source and the RFID circuitry.
 101. Thesystem of claim 94, wherein the printing apparatus is operative to:receive control signals, the control signals control the feed of theribbon, the transfer printing, and the programming.